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Got a little more progress for you all. I was still really nervous about this backpack sculpt and felt like I was paddling down uncharted territory (which I was...for me at least) due to the size and shape of this mold. This is by far the most complex and complicated piece (forming-wise that is) that I've ever set out to do and I really didn't know if it was even going to work until I did a few pulls... everything up until that point has been strictly theory not to mention this piece is so tall and deep as well as oddly shaped for a pull that webbing and stretch of the plastic was certainly a major concern.

Honestly I thought I was taking a huge risk and wasting a lot of time and resources on this but I had to at least try and see what would happen....and boy am I glad I did and I'm glad to say that I'm super pleased with the results.

Not only was I worried about getting it to form, but I also didn't know if this funky shape was going to allow me to release the plastic from the mold. Happily, my theories on the angles were correct (either that or I just Forrest Gump'd my way through this one lol :P) and the mold practically fell out of the plastic

My biggest reason for making the frame in one piece was for easier assembly and for strength and I really hope that I have achieved this as well as keeping it as accurate as possible (being super anal helps too :P)

Take a look at the pics below as well as the side by side 'paint' photo I assembled and let me know what you think. Keep in mind that this piece is still in the early stages and there are a few things I still need to do to it to tweak it a bit, but I think for the most part the shape is correct.

Enjoy!

Obviously I still need to make the outer 'floating' pieces and this is just the under frame, but this side by side will explain things better than I can with words

I've still got those 'floating' pieces to sculpt (and they really shouldn't take long at all) but at least the hardest part is behind me now (relatively speaking )

Here's a couple of teaser shots... still need to clean this mold up so it's still a bit rough, but at least it gives you all a better idea of which direction I'm moving with this ...slowly making progress

wow, my wallet could be your best friend... this looks great. gonna need one in the future bro

Hehe, thanks bro! I could see your wallet being my best friend as well lol :P

I know it's been a while since my last update, been super busy with orders and ...well just life in general, but I am making progress on this. I hope I'm going in the right direction with this backpack, but as usual I like to hear all your feedback. Please keep in mind that this was a quick mock up and the pieces are haphazardly held together with tape, so they're not placed perfectly and are not keeping their proper positions
On a related note, what's the general consensus on the SB backpack pouches? Are they considered accurate size wise? They seem a bit on the small(ish) side to me, but I always like to get another opinion. The reason for my question is because I'm at a point where I need to decide what to do with the lower portion of the pack frame, and I'd like to make this compatible with those pouches (for those who already own them) if they are indeed accurate. LMK!
Here's some pics, enjoy!

We'll call this Version 2 of the pack frame (if you will).
Just made some minor adjustments to it as well as added (GASP) mounting tabs to the sides
Simply line up the pack to where you want it to sit on the backplate and then make your marks and cut some slots to insert the tabs The first test of this worked really well and I was very pleased with the results. Keep in mind though, the one in the pic has a few issues going on with it - 1. I had already cut slots into it from the V1 pack frame so they're off a bit and 2. the tabs on this particular V2 were cut a bit too short, but you get the idea. Notice too that I also made the tabs as part of the flares for the mold so they angle outward and flatten out a bit to conform better to the inside of the backplate so they're not stabbing you in the back. Once properly secured, they pull the edges nice and snug along the most of the entire surface of the plate. So far I'm pretty happy with the results, take a look!
For these next pics I just threw the outer pack shell on top to see how it looks. The PVC coupler is sitting on it for size reference only as well...it's just under 3" inches in diameter (outer) which is what I'm looking at for this pack. I'll mock up some foam boxes soon for the total look and see where I'm at (will post pics of that too when I get to it )

OK got a few more thousand words for you all. I did a few more pulls after tweaking the backplate outer shell mold and the side canisters (made them shorter by about a 1/2" inch) and then worked up some mock pouches out of foam for a size check (let me know what you all think about the size on them boys too) and did a quick dry fit of everything for a snapshoot Also threw on a pvc pipe (even though it's still a bit too narrow...still looking for the 3" inch diameter stuff), just for grins to see it all put together. Take a look:

Not too much to report, but I did get a few pouches sculpted up real quick tonight. They're pretty much ready for rubber. I'm also gonna be hitting a few places in town today to see about sourcing some larger PVC pipe for a more correct look. I'll likely be vacc'ing the rear canister detail (with the raised lines/ribs on it) as an extra piece to cover it for a nicer look...was thinkin of going with .040 white styrene
Here's pics in the meantime:

Poured the masters for the backpack pouches in resin today. I was surprised at how easily the clay originals came out of the mold and that they retained their shape as well as they did..I thought for sure they'd have been destroyed trying to get them out. Here's a pic!
Up next, copies in foam. Will be the first time trying that medium out, so got some experimenting to do

Some more progress - All I pretty much have left to do is make the end caps for the detonator and get some better material to make the pouches. On the pouches: I was able to make a few slush cast and then back fill them with foam (albeit the wrong kind of foam, but at least I know the method works). I really like the way they came out but I still need to do something about the back in order to make them mountable to the pack. If I can't find the right type of foam for these, this may end up being the way I offer them. I'm not giving up yet though, I ordered another type of foam from Smooth on and hope to have it by the end of the week or early next week. According to their description of what this stuff does, it should be the solution...but we'll see. In the meantime, here's pics
I made a slight change to the outer/upper shell to make it a bit more accurate...I'm much happier with it now (cause it was bugging the cr@p out of me :P)
Here's what I wound up doing for the det. I kinda like it and it was a simple solution
And the rest all together

OK guys (and gals of course), I just about got this backpack knocked out. I'll be making these available in a day or two after I find out if my 'caster' has been able to pump out some pouches for me (I've only got like 2 on hand at the moment). Keep in mind, in the pics below of the kit is just a dry mock up for sale thread purposes only so the placement is not ideal, but you get the idea. Hope you all like it!

That's pretty much it for now. I still need to assemble one of these for a vid tutorial, but honestly I don't know when that'll be. I need a break...totally burned out right now :/

Thanks a ton beans
You nailed it when you said "And a lot more to do" lol...too true. Well, one piece at a time, but eventually I'll get there. The hardest part is just sticking with it week after week when a lot of times it just doesn't feel like I'm making any progress at all...then BAM, I do a photo shoot like this last one for the pack and it looks like it's starting to come to life.
As always, thanks for looking and stay tuned!